Natural fiber-based insulated panel and temperature controlled shipping system

ABSTRACT

A natural fiber-based insulating panel system to facilitate shipping. One or more natural fiber-based panels are inserted into the interior of a shipping container to encapsulate the payload, or on the exterior of the shipping container to encapsulate the shipping container and payload. A film or membrane may encapsulate one or more of the insulating panels. Micro perforations may be present in the membrane to facilitate the capture of moisture from the interior.

BACKGROUND Field of the Invention

The present invention relates generally to a natural fiber-based insulated panel and temperature controlled shipping system, and more particularly, to panels that can be constructed from a natural fiber material such as hemp, and that maintain a rigidity level that allows them to be inserted into shipping containers and or be formed into shipping containers.

Background

Consumers and industry players alike are demanding temperature-controlled shipping systems that are more and more environmentally friendly. This is especially true in view of the Covid-19 pandemic during which the world sheltered in place and began to order all life's necessities on-line. This live change has resulted in an increase in the demand for temperature-controlled shipping systems, which, in turn has resulted in greatly impacting the amount of refuse generated due to such demand. Currently, there are a number of solutions for temperature-controlled shipping systems on the market. Some of these solutions attempt to use expanded polystyrene (EPS) or polyurethane insulation as insulating panels, but these solutions fail to meet the needs of the industry because of the hugely negative environmental impact that petroleum-based insulated panels and containers have both during their manufacture and in their post-use disposal. The manufacture of these petroleum-based insulating panels requires high amounts of energy and chemicals and results in pollution from the chemical processing. These petroleum-based insulating panels are bulky, essentially non-recyclable, and continue to clog our landfills and waterways. Other solutions attempt to replace petroleum-based insulation with insulating panels made from cotton fibers or paper. But these solutions are similarly unable to meet the needs of the industry for an environmentally-sound shipping systems because of the high levels of energy and chemicals used in the manufacture of the insulating fibers and the resulting pollution from the chemical processing. Still, other solutions seek to form insulating panels out of bio-based starches, but these solutions also fail to meet industry needs because of the energy and chemicals used in their manufacture, and the poorer thermal performance provided by the bio-based starch insulating panels.

Thus, there is a need in the art for a solution that provides sufficient insulation for items being shipped or stored, that is versatile, that provides a level of protection against shock or vibration and that is environmentally sound.

BRIEF SUMMARY

Embodiments of the present invention include a system and method for controlling the temperature of packaged goods during transportation (or storage). In various embodiments, the system may include a unique combination of insulating panels and optionally a shipping container. The system utilizes insulated panels formed from natural fibers (such as hemp fibers and/or other natural fibers), placed within the interior or on the exterior of a shipping container or payload, to form a thermal barrier around the goods being shipped, thereby helping to keep the goods at a more optimum and consistent temperature during transportation or storage. In an exemplary embodiment, the components ay include: hemp and other plant-based fibers that are formed into insulating mats or panels, such as through mechanical processing, however, in some embodiments, chemical processing may also be performed in addition to or in lieu of the mechanical processing. Exemplary embodiments of the insulating mats or panels of natural fiber or hemp-based insulation may vary in thickness depending on the particular application. In various embodiments, the thickness may range from less than 0.5 inches to 2 or more inches. In a particular embodiment, the thickness of the insulating panel may be approximately 1.5 inches in thickness. Further, the insulation panels may be cut to a size and shape that can be inserted into or wrapped around a box, payload or other shipping container so as to cover each of the sides of the container or payload and thus, encapsulate the payload or container. In some embodiments, the individual insulated panels can be wholly encased or partially covered by a plastic, bio-plastic, paper or other film to enhance the overall performance of each insulated panel. The various embodiments can be used to form a thermal barrier between the space inside the shipping container and the outside environment, thus creating an environmentally friendly, temperature controlled shipping system that is recyclable and compostable after use. Furthermore, it should be noted the manufacture of the hemp and other natural fiber insulated panels described in this invention use far less energy and chemicals to produce than conventional expanded polystyrene (or extruded polystyrene)-based, paper-based or cotton-fiber-based insulation. Insulated shipping systems formed using the insulated panels described herein thus have a substantially lower impact on the environment than other existing thermally-controlled shipping solutions.

In an exemplary embodiment of an insulated shipper (including a shipping container and one or more insulation panels) the shipper is an essential part of a temperature-controlled packaging system used to ship temperature-sensitive products such as food items, organs, drugs and other perishable products. Traditionally, petroleum-based insulation materials, such as expanded polystyrene (EPS) foams and polyurethane foams have been used as the main insulating material for temperature-controlled shippers. These existing conventional shippers are not environmentally-friendly. They are petroleum-based, contribute to pollution during their manufacture, and continue to be an environmental problem after their use. Most conventional shippers are not reused or reusable, are not biodegradable and result in clogging landfills. In the recent years, a growing number of bio-based insulated shippers offering some level of compostability and/or recyclability have come on the market. The insulation used in these new shippers is most often based on paper or cotton fiber. Although these more recent offerings are somewhat more environmentally friendly than petroleum-based insulation, the harvesting and processing of the raw materials used to manufacture these non-petroleum-based insulation products present an ecological and carbon footprint that is not optimum. Large amounts of energy, chemicals and water are required to process cotton and wood fiber (paper) into usable insulation. The chemicals used in the processing of these fibers lead to post-process waste streams that pollute the environment. Additionally, the growth and processing of cotton is one of the most water-intensive, chemical-intensive and energy-intensive of all natural fibers. Accordingly, there is a need for bio-based insulation that: is rapidly-renewable; sequesters more CO2 per unit of usable fiber; uses less pesticides, fertilizers and water during growth; and uses less energy and chemicals during processing of the plant fibers into usable insulation; and generates less chemical pollution. The disclosed device and associated method advantageously fill these needs and other considerations. Various embodiments of the present invention address the aforementioned deficiencies by providing a recyclable and compostable, natural fiber or hemp-based insulation and temperature-controlled packaging system that has insulating and temperature control properties on par or better than existing solutions, while at the same time: sequestering more CO2 per pound of insulation fiber; using less pesticide, fertilizer and water during growth; using less energy, chemicals and water during manufacture; and creating less chemical pollution during processing of the plant fibers into usable insulation.

The present disclosure thus presents embodiments of a temperature-controlled shipping system, which may include the following components: insulating mats or panels that are flexible yet dimensionally-stable, made primarily of natural fibers or hemp fibers or a combination of hemp fibers and other mechanically-processed natural fibers, and a box or other shipping container into which or around which the insulating panels are placed. These components are arranged in such a manner that the insulating panels form a continuous or nearly continuous layer inside or around the shipping container or payload, thus creating a barrier to heat transfer between the inside of the shipping container and the outside environment. The contents inside the shipping container are thus kept at a more optimum and consistent temperature during transportation or storage.

The hemp or other natural fiber insulation is manufactured using little or no chemicals in the processing of the harvested plant biomass into insulating fibers. The harvested and retted natural fibers, such as hemp straws, are mechanically decorticated to separate the desired type of natural or hemp fibers. In some embodiments, the fibers are further processed with a binding agent being mixed with the natural or hemp fibers and heated to a specific temperature whereby the binding agent melts and holds the mixture together. The resulting mat is compressed to the desired material density and maintains both its flexibility and dimensional stability after cooling. It should be appreciated that other manufacturing techniques are also anticipated. As needed, the mat is then cut into panels to fit a specific shipping container or payload. The flexibility of the insulating panels allows them to be folded so that the panels can adapt to the interior or exterior of the target shipping container. Further, the panels can be scored or sculpted to further facilitate the ability to be folded. The mats and panels so formed are reusable, recyclable and compostable.

The various embodiments may also include one or more of the following: To limit convective movement of air through the insulating panels and improve their thermal performance, the insulating panels may be wholly or partially wrapped in a film, coating, cover or membrane (herein collectively referred to as film) such as low-density poly ethylene (LDPE), kraft paper, bio-plastics or other materials. The film may be perforated or include a plurality of apertures to allow the flow of moisture from the payload inside the shipping container into natural or hemp fibers, thus enabling the moisture-absorbing natural or hemp fibers to regulate the moisture content in the packaging system. The perforations will also eliminate trapped air pockets in the insulating panels that could interfere with the folding and assembly of the insulating panels into or around the shipping container.

The material used to bind the insulating fibers may be 100% polyester or a mixture of polyester and other synthetic fibers. Alternatively, in order to improve end-of-life recycling and composting options, bio-based binders such as Polylactic acid (PLA) may be used. In an exemplary embodiment, the quantity of hemp fibers is substantially greater than the quantity of the binder by volume. As a non-limiting example, the content of binding fibers in the insulated panel may be less than 10%, such as 8% polyester and 92% natural or hemp fibers. In other embodiments, the insulated panels may include more than 10% of the binding fibers by volume or less than 10% of the binding fibers by volume. Further, in an exemplary embodiment, the insulated panels may include 90% natural or hemp fibers but, in other embodiments the insulated panels may include more or less than 90% natural or hemp fibers. In some embodiments, the ratio of natural fibers or hemp fibers to binder may be uniform throughout the insulated panels. However, in other embodiments, the ratio of natural or hemp fibers to the binder may vary throughout the insulated panel. For instance, the ratio may be modified to improve the rigidity along the perimeter of an insulated panel, to increase the thermal characteristics of a certain area of the insulated panel, to increase the flexibility of a portion of the insulated panel (i.e., along a fold line), etc.

For instance, in another embodiment, insulated panels may be fabricated with 40% or more natural or hemp fibers. In yet another embodiment, insulated panels consist of more than 40% natural or hemp fibers and approximately 10% polyester or binder. In yet another embodiment, the insulated panels may consist of 40% or more natural or hemp fibers and approximately 10% or less polyester or binder. In yet even other embodiments, the insulated panels may consist of approximately 46% hemp, approximately 46% post-industrial virgin paper fiber and 8% polyester. Such embodiments advantageously can be fabricated at a lower cost, produce less dust in the manufacturing process, and provide an improved thermal performance. It should be appreciated that other variations in fabrication of the insulated panels may also be implemented in the various embodiments.

In the various embodiments described herein, the insulated panels may be constructed of natural fibers, hemp fibers or include a mix of hemp fibers with other natural fibers and/or machine created fibers. While various embodiments may be described as using hemp fibers, it should be appreciated that this is only provided as a non-limiting example and other natural fibers may also be suitable for such embodiments. However, with the increase in the interest of growing hemp, the various embodiments are described as utilizing hemp fibers. And while other natural fibers may be substituted, it should be appreciated in the use of hemp fibers or combinations of hemp with other natural fibers may in and of itself comprise a patentable element in various embodiments.

To form an insulated shipping system, the natural fiber insulating panels can be installed on the inside or outside of the shipping container. The shipping container may be comprised of a single container of almost any shape such, as a cardboard or plastic box, tube, can or drum. The shipping container could also be comprised of multiple individual shipping containers assembled into a whole, such as a pallet of several boxes or containers, which is then wrapped with one or more insulating panels.

The insulating panels, which are placed on the inside or outside of a box shaped shipping container, can be configured in numerous ways, including but not limited to:

A 2-panel system whereby each insulating panel covers three sides of the shipping container,

A 3-panel system whereby one insulating panel covers the bottom surface of the shipping container, one insulating panel covers the top, and one long insulating panel covers the 4 vertical sides of the shipping container,

A 6-panel system whereby there is an independent insulating panel for each side of the box.

A stacked panel system whereby 2 or more insulating panels are stacked on top of each other inside the shipping container. One or more of the stacked panels may have one or more cutouts to hold products such as bottles, vials or other packages. Additional cutouts could be made to hold devices that would further enhance the temperature stability of the overall system such as: gel-packs for cooling, dry-ice for cooling, and phase change materials for hot or cold temperature control.

A wrap-around system whereby insulating panels are wrapped on the outside of the shipping container or assembly of shipping containers.

It should be appreciated that other shaped containers and/or payloads can be equally addressed in various embodiments. As a non-limiting example, a two-piece spherical insulating panel system can be utilized for round objects. Other shapes and sizes are also anticipated by the various embodiments of the invention in that the panels can be sized and shaped for any application. It should also be appreciated that while the various embodiments refer to insulating panels, the panels are not necessarily always flat panels. In some embodiments the panels may be three-dimensionally shaped and include a variety of contours and surfaces.

A material, such as an adhesive or a device such as VELCRO or other hook and loop material may be used along the edges where the insulating panels meet so as to minimize any gaps between the assembled insulating panels. Further, in some embodiments the edges of the insulating panels may be configured to be interlocked, such as with a series of teeth and gaps that allow the panels to be secured together and may improve the overall thermal retention of the enclosure.

The various embodiments are unique when compared with other known devices and techniques because they provide a temperature controlled shipping system consisting of natural or hemp-based fiber insulating panels (comprised of hemp and possibly other natural fibers plus a binding agent) and a shipping container: (1) that is more environmentally friendly than other shipping systems since during the manufacture of the insulating fibers and the insulating panels: fewer chemicals, less water, and less energy is used; less chemical pollution is created; and more CO2 is sequestered; (2) where the natural fiber or hemp-based insulating panels are reusable, compostable and/or recyclable; (3) where the natural fiber or hemp-based insulating panels are able to absorb moisture; (4) where the film or membrane that may encapsulate the natural fiber or hemp-based insulating panels, either wholly or in part, is perforated or includes apertures to allow moisture to pass from the interior of the shipping container into the hemp-based insulation, thus helping to prevent the buildup of potentially harmful moisture inside the shipping container; (5) where the natural fiber or hemp-based insulating panels are able to absorb some mechanical shock during transportation, thus helping to prevent damage to the goods in the shipping container; (6) where the shape-stable yet flexible nature of the natural fiber or hemp-based insulating panels allows for a high degree of flexibility in the specific configuration of the insulating panels inside or around the shipping container.

Similarly, the various methods presented here are unique when compared with other known processes and solutions in that: (1) the methods of mechanically processing the natural fiber or hemp plant fibers into fibers usable for insulating panels uses fewer chemicals, uses less water, uses less energy, creates less chemical pollution and sequesters more CO2 than other types of bio-based fibers such as cotton and paper; (2) the specific formation of the natural fiber or hemp fibers and the combining of those fibers with a binding agent is done in a way whereby the resulting un-encapsulated insulating panel: has excellent insulating properties, is shape stable yet flexible, is able to absorb moisture, and is reusable, recyclable and compostable; (3) the combining of the raw natural fiber or hemp insulating panels with an encapsulating film is done in a way whereby the resulting encapsulated insulating panel is shape stable yet flexible, is able to absorb moisture, and is recyclable and compostable.

The disclosed embodiments are unique in that they are structurally different from other known devices or solutions. More specifically, the embodiments are unique due to: (1) the use of natural fibers or hemp fibers to create insulating panels for use in an insulated, temperature controlled shipping system; (2) the encapsulation of those insulating natural fiber or hemp panels, either in whole or in part, with a film that reduces the amount of particulate matter that sheds from the natural fiber or hemp insulating panels during use; (3) the encapsulation of those insulating natural fiber or hemp panels, either in whole or in part, with a breathable film; (4) the use of an encapsulating film that is recyclable and/or compostable; (5) the use of insulating natural fiber or hemp panels that incorporate a type of natural fiber or hemp fiber and an amount and type of binder agent that allows the resulting insulating panel to be compostable and/or recyclable; (6) the use of insulating natural fiber or hemp panels that are able to absorb moisture; (7) the use of insulating natural fiber or hemp panels that are able to bend and flex at least 90 degrees or more, while not breaking and still maintaining their insulating properties; (8) the use of insulating natural fiber or hemp panels that are shape-stable and have the ability to maintain their shape and overall structure when portions of the insulating panel are cut out (for example, a circular cut-out in the center of an insulating panel) thus creating an interior cavity in which a product (for example, a bottle of temperature sensitive liquid) can be both thermally and mechanically protected during transportation; (9) the fact that the shipping system consists of a unique combination of a container (for example, a box) and natural fiber or hemp-based insulating panels (encapsulated, partially encapsulated or un-encapsulated) placed in the inside or on the outside of the shipping container, that reduces heat transfer between the interior of the container and the external environment.

Furthermore, the processes associated with the aforementioned embodiments re likewise unique. More specifically, the disclosed processes owe are unique due to the fact that: (1) the insulating natural fiber or hemp panels are formulated using a type of natural fiber or hemp fiber and an amount and type of binder agent that allows the resulting insulating panel to be compostable and/or recyclable; (2) the insulating natural fiber or hemp panels are formulated in a way whereby are able to absorb moisture; (3) the insulating natural fiber or hemp panels are formulated in a way whereby the natural fiber or hemp panels that are able to bend and flex at least 90 degrees or more, while not breaking and still maintaining their insulating properties; (4) the insulating natural fiber or hemp panels are formulated in a way whereby they are shape-stable and have the ability to maintain their shape and overall structure when portions of the insulating panel are cut out (for example, a circular cut-out in the center of an insulating panel);

This disclosure now provides a more detailed and specific description that will refer to the accompanying drawings. The drawings and specific descriptions of the drawings, as well as any specific or alternative embodiments, functions, aspects and/or characteristics discussed, are intended to be read in conjunction with the entirety of this disclosure. The hemp and other natural fiber-based insulated panel and temperature controlled shipping system may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and fully convey understanding to those skilled in the art.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a perspective exploded view of an exemplary embodiment of a 2-panel system whereby each insulating panel covers three sides of the shipping container.

FIG. 2 is a cross-sectional view of an exemplary embodiment of an insulating panel suitable for various embodiments of the invention.

FIG. 3 is a perspective exploded view of an exemplary embodiment of a 3-panel system whereby one insulating panel covers the bottom of the shipping container, one insulating panel covers the top and one long insulating panel covers the 4 vertical sides of the shipping container.

FIG. 4 is a perspective exploded view of an exemplary 6-panel system whereby there is an independent insulating panel for each side of the shipping container.

FIG. 5a is a perspective exploded view of an exemplary stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as phase change material) that will help maintain the temperature inside the shipping container.

FIG. 5b is a see-through perspective exploded view of the stacked panel system of FIG. 5a , wherein 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container.

FIG. 6 is a perspective exploded view of a stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having a rectangular cut-out to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container.

FIG. 7 is a perspective exploded view of a wrap-around system whereby insulating panels are wrapped on the outside of the shipping container or assembly of shipping containers.

FIG. 8 is a perspective exploded view of a 3-panel pallet cover system whereby one insulating panel covers the bottom of the palletized payload and two panels cover two opposite sides of the palletized payload with two superimposed panels on top of the palletized payload.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

The present invention, as well as features and aspects thereof, is directed towards providing a hemp and/or other natural fiber-based insulated panel or panel system, as well as a temperature controlled shipping and/or short term storage system utilizing one or more of the insulating panels.

An exemplary embodiment of a device or shipping/storage container may include the following components: one or more properly sized, shape-stable insulating mats or panels made from natural fibers or hemp fibers and binders, that may be wholly or partially covered with a recyclable and/or biodegradable, perforated outer film, and assembled into one or more shapes that fit snugly together when placed into the interior or onto the exterior of a shipping container or assembly of several shipping containers or a payload. The result is a continuous or nearly continuous insulating layer that reduces the rate of heat transfer between the items in the interior of the container and the environment outside the container. The system thus better preserves the quality of temperature-sensitive goods that may be shipped or stored utilizing the device. The combination of the natural fiber or hemp insulating panels and the shipping container create a unique system that provides a superior system for transportation of thermally-sensitive goods. The addition of cold-packs (typically containing a phase change material such as frozen water with certain chemical additives, or frozen CO2) into the interior of the shipping container creates a system that can maintain a favorable temperature inside the shipping container for an extended period of time. Likewise, heat packs, such as packets containing iron, activated carbon and water, may be used to maintain the items at a warm temperature.

By using hemp and/or other natural fiber-based insulation, this shipping system is recyclable, biodegradable, and is more environmentally friendly than other shipping systems.

It should further be noted that, due to the moisture absorbing properties of the natural fiber or hemp insulation being used, and the presence of perforations in the film covering the natural fiber or hemp insulating panels in whole or in part, the insulating mats reduce the accumulation of moisture on the inside of the shipping container that may otherwise take place if other insulating materials are used. This in turn, leads to better preservation of the quality of the goods inside of the shipping container during transportation.

It should also be noted that unlike some other insulating materials, the natural fiber or hemp fiber insulation helps absorb shocks and vibration occurring during transportation. Advantageously, this aspect of the various embodiments provides an improved protection of the goods being transported.

It should also be noted that should the natural fiber or hemp insulation become moist or wet, the insulating properties of natural fiber or hemp insulation degrade much less than other types of bio-based insulation. Advantageously, this can result in better thermal protection of the good being transported.

It should also be noted that because of the semi-ridged structure of the natural fiber or hemp insulation, stable cut-outs can be made in the hemp insulation which will allow for a customized space in which the goods being transported can be placed. These specialized cut-outs may provide for easier assembly of the goods into the package prior to shipping and also better protection of the goods during transport. Furthermore, the cut-outs from the hemp panels can be readily put back into the feed-stock for manufacture of additional mats with almost zero wasted material.

It should also be noted that the film placed on the outside of the natural fiber or hemp insulation may include a reflective surface on one or both sides to enhance the insulating properties of the insulating mat or panel.

It should also be noted that the use of a film or covering on the outside of the natural fiber or hemp insulating mat is not a requirement. The natural fiber or hemp mats or panels without a covering have excellent insulating properties.

It should also be noted that the performance of the shipping system may be further enhanced by placing the temperature sensitive goods along with the phase change materials inside a sealable bag before placing the goods inside the insulated shipping container.

It should also be noted for embodiments that specifically include hemp, that because of the nature of hemp cultivation and hemp fiber processing, the hemp insulation requires fewer acres of cultivated land or space than other fibers, such as cotton, to yield a similar amount of usable insulation (same area of insulation with same insulating properties). When compared with the production of other insulation materials, for each unit of usable insulation, hemp sequesters more CO2, uses fewer chemicals, uses less water and creates less chemical pollution. This may also be true for other natural plants for producing natural fibers.

An exemplary form of performing the creation method associated with the disclosed device may include the following steps: natural fiber or hemp fibers manufactured from sustainably grown plants, mechanically processed into fibers using little to no chemicals (or an unsubstantial amount of chemicals), with such fibers then combined with a quantity and type of binder chemical so that the resulting fiber-binder mix is compostable and recyclable, with that same fiber-binder mix then processed using heat, pressure and other means into a shape-stable insulating mat. One or more of these insulating mats are then trimmed, optionally covered in whole or in part with a breathable exterior film and assembled into one or more shapes that fit tightly together when placed into the interior or onto the exterior of a shipping container, or assembly of several shipping containers or payload. The result is a continuous or nearly continuous insulating layer that reduces the rate of heat transfer between the items on the interior of the container and the environment outside container.

Referring now to figures in which like labels represent like elements throughout the several views, further exemplary embodiments, functions, aspects and characteristics of the various embodiments are presented.

FIG. 1 is a perspective exploded view of a 2-panel system whereby each insulating panel covers three sides of the shipping container. The exploded view perspective of a 2-panel system 100 includes two insulating panels (120 and 130) whereby each insulating panel covers three internal sides of the shipping container 110, all insulating panels containing natural fibers or hemp fibers as shown in FIG. 2. The first insulating panel 120 is C-shaped or folded into a C-shape form from and unfolded flat form and inserted in the shipping container 110 in such a manner that it covers the bottom, one vertical side and the top of the payload 140 inside the shipping container 110. The second insulating panel 130 is also C-shaped or then folded into a C-shape form from an unfolded flat form and inserted into the shipping container 110 in such a manner that it covers the three remaining sides of the payload 140 inside the shipping container 110. The two C-shape insulating panels (120 and 130) are arranged in a way whereby they define an interior cavity for receiving and housing the payload 140 and, they form a continuous or nearly continuous layer inside the shipping container 110, thus creating a barrier to heat transfer between the inside and the outside of the 2-panel system 100. The payload 140 inside the shipping container 110 is thus kept at a more optimum and consistent temperature while within the cavity defined by the 2-panel system, such as during transportation or storage. A device or several devices such as phase change materials (not shown) may be added between the payload 140 and the interior surfaces of the insulating panels (120 and 130) to maintain a certain temperature range for a certain duration. A Phase Change Material (PCM) provides advanced thermal protection when shipping or storing temperature-sensitive products. When PCMs melt and freeze, or change phases of matter between solid and liquid, they maintain a constant temperature equal to their melting/freezing point. A phase-change material suitable for packaging is generally an organic or inorganic substance that acts as a payload's heating or cooling agent. As the payload's temperature increases or decreases (depending on several factors, from ambient external temperature to the type of insulation being used), the PCM works to maintain a stable, consistent temperature for the duration of its trip or storage.

There are several commonly used phase-change materials within the shipping industry, and each comes with its own benefits and drawbacks. It should be noted that a PCM alone is not effective in maintaining temperature, as the PCM should be utilized in conjunction with a packaging and insulation system. As a participant in the temperature regulator for packaging systems, however, it's important to choose a PCM carefully. For example, the following considerations should be examined in selecting a PCM:

If a payload needs to be kept at a particular temperature or temperature range, such as at 14° C., with acceptable excursions ranging from 11° C. to 17° C., a PCM should be selected to maintain the temperature within that range.

If the payload requires a consistent temperature for a particular period of time, such as 24 to 48 hours or if the payload has an extended travel/storage period, such as 120 hours, a PCM should be selected to that meets these characteristics.

If the payload vibration or shack sensitive, special packaging solutions may be examined to provide sufficient room for and protection of the payload for the duration of the trip. For example, using dry ice as a PCM may be effective for materials that need to be kept frozen (below −18° C.). However, once the ice sublimates, it results in creating room for the payload to move around and possibly become damaged.

Creating contours or cut-outs in the insulating panels can advantageously alleviate issues that may arise in this scenario.

If the cost of shipment is a concern, a packaging solution or PCM as a more expensive option may not be the best suited for the particular shipping needs. Reusable solutions also may appear more expensive, but based on cost per use may be more affordable.

If environmental impact is a concern, an appropriate PCM can be selected. For instance, determining what the PCM composed of, and if it is renewable. Further, it should be determined if the PCM is toxic or non-toxic and if it can be used repeatedly.

There are several types of technology utilized for PCMs. A few non-limiting examples include:

Water-based gel packs. Water-based gel packs are among the most inexpensive forms of PCMs available. However, and gel packs can sometimes provide inconsistent temperature control. Gel packs also may need to be conditioned hours before use to avoid thermally shocking the payload. They are, however, non-toxic, and intact gel packs may be used several times.

Dry ice (frozen CO2). This PCM option is also inexpensive and readily available (but not reusable). Dry ice works well with deep frozen payloads traveling short distances. Using dry ice as a PCM requires careful packing to ensure payloads remain safe even as the dry ice sublimates. Thus, the use of cut-outs or contours suitable for the payload may be required.

Vegetable oil-based PCMs. This PCM technology can achieve virtually any temperature range and maintain it for extended durations of time. Vegetable oil-based PCMs are also biodegradable, non-toxic, and experience no thermal degradation after many uses.

Petroleum-based PCMs are derived from crude oil. The cost of this PCM technology thus fluctuates with the price of crude oil similar to the price of gasoline. Depending on the petroleum derivative used to create the PCM, most are toxic and thus, disposal of them may be difficult.

Heavy water (deuterium oxide). This PCM technology is very useful for refrigerated payloads (such as items that need to be maintained at a range of 2−8° C.). The heavy water PCMs freeze at 3.82° C. While this technology is quite effective as a PCM, it must be used with caution, may be difficult to obtain and can be costly.

Eutectic salts. A generic term for many materials that contain a salt in solution at a concentration that yields the lowest freezing point, eutectic salts can vary in safety, price, and effectiveness, based on their composition. There may also be disposal or customs issues, based on the material used.

One or more of the insulating panels may or may not be encapsulated, in whole or in part, in a plastic film or a film made of other materials, and the film may be perforated or not. In one particular and illustrative, yet non-limiting, embodiment of the 2-panel system 100, the unfolded insulating panel 120 may have a length of approximately 35 inches, a width of approximately 12 inches and a thickness of approximately 1.5 inches whereas the unfolded insulating panel 130 may have a length of approximately 32 inches, a width of approximately 9 inches and a thickness of approximately 1.5 inches. Of course, these measurements are merely illustrative and insulating panels of any length, width and thickness that include the features described herein are intended to be within the scope of the various embodiments of the invention and disclosure, which has many different embodiments. In this and all other embodiments, a material such as an adhesive or a device such as a hook and loop material (eg, VELCRO) may be used along the edges where the insulating panels meet so as to minimize any gaps between the insulating panels. In other embodiments, at locations where an edge of a first panel rest on the surface of a second panel, a groove can be formed in the surface of the second panel so that the edge of the first panel can rest within the groove creating a tongue-in-groove construction. Further, the adhesive or loop and hook material may also be applied to the edge and groove to further secure the panels in place. The payload 140 is shown for illustrative purposes and is not part of the 2-panel system.

FIG. 2 is a cross-sectional view of an exemplary embodiment of an insulating panel suitable for various embodiments of the invention. Referring to FIG. 2, a cross-sectional view of an exemplary insulating panel 200 includes a mat made primarily of natural or hemp fibers 230 and a film 210 in which the insulating panel 200 may be wholly or partially encapsulated. In the illustrated embodiment, the encapsulating film 210 includes an array of micro-perforations or apertures 220 on one side that faces the payload 140 once inserted in the shipping container 110. In some implementations, the micro-perforations 220 are present on the entire film 210 while in other embodiments, the micro-perforations 220 are present on portions of the panel that are adjacent to and/or proximate to the payload 140. In various embodiments, the encapsulating film 210 may be constructed of plastic, bio-plastic, paper or other materials. In some implementations, the film 210 may also include a reflective surface on one or both sides to enhance the insulating properties of the insulating panel 200. In some implementations, the insulating panel 200 is not encapsulated with an encapsulating film 210. In some embodiments, the film may be a stand-alone material that is applied to the hemp fibers 230, or a sheath that is slid over the hemp fibers 230 or even a material that is sprayed onto the hemp fibers and then perforated after application. In some embodiments, the film may be naturally porous or configured such that moister or air may pass through the surface, while in other embodiments the film may be water and/or air tight. In some embodiments, super-absorbent beads may be included between the film 210 and the natural or hemp fibers 230 for further facilitate the collection of moister. In other embodiments, the film 210 may include pockets for housing super-absorbent beads or material such that the pockets can be removed for proper disposal while the remainder of the material can be recycled.

FIG. 3 is a perspective exploded view of an exemplary embodiment of a 3-panel system whereby one insulating panel covers the bottom of the shipping container, one insulating panel covers the top and one long insulating panel covers the 4 vertical sides of the shipping container. Referring now to FIG. 3, the illustrated 3-panel system 300 in accordance with an exemplary embodiment of the invention is shown as including three insulating panels (310 and 320) and a shipping container 110. In the illustrated embodiment, the combination of the three panels cover all internal walls of the shipping container 110. The insulating panels may be primarily constructed of natural fibers or hemp fibers as shown on FIG. 2. In the illustrated embodiment, one insulating panel 310 covers the bottom of the shipping container 110, one insulating panel 310 covers the top of the shipping container 110 and one long insulating panel 320 covers the 4 vertical internal walls of the shipping container 110. To assemble the 3-panel system 300, the insulating panel 310 is inserted flat at the bottom of the shipping container 110. The insulating panel 320 is then inserted inside the shipping container 110 and folded in a way that it covers the four internal vertical sides of the shipping container 110 with each fold or the meeting junction of the edges of the long insulating panel 320 being inserted into the corners of the shipping container 110. It should also be appreciated that the insulating panel 320 may be constructed as a box without a top or bottom and then slid into the shipping container or over the payload. The insulating panel 310 is added on top of the insulating panel 320 to form a continuous or nearly continuous insulating layer inside the shipping container 110 which surrounds the payload 140 being transported. A device or several devices (such as gel-packs containing phase change materials) may be added between the payload 140 and the insulating panels (310 and 320). The payload 140 is shown for illustrative purposes and is not part of the 3-panel system.

FIG. 4 is a perspective exploded view of an exemplary 6-panel system whereby there is an independent insulating panel for each side of the shipping container. Referring now to FIG. 4, the exemplary 6-panel system 400 includes 6 insulating panels (3 styles 410, 411, 412) and a shipping container 110 whereby there is an independent insulating panel for each internal side of the shipping container 110. All insulating panels are primarily made of natural fibers or hemp fibers such as shown on FIG. 2. To assemble the 6-panel system 400, one of the insulating panels 410 is inserted flat at the bottom of the shipping container 110. The insulating panels 411 are then inserted inside the shipping container 110 and laid against two opposite vertical walls of the shipping container 110. The insulating panels 412 are then inserted in the shipping container 110 and laid against the two remaining opposite walls, orthogonally to the insulating panels 411, of the shipping container 110. The remaining insulating panel 410 is added on top of the vertical insulated walls 411 and 412 to form a continuous or nearly continuous insulating layer inside the shipping container 110 which surrounds the payload 140 being transported. A device or several devices such as phase change materials may be added between the payload 140 and the insulating panels (410, 411, 412). The payload 140 is shown for illustrative purposes and is not part of the 6-panel system.

FIG. 5a is a perspective exploded view of an exemplary stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as phase change material) that will help maintain the temperature inside the shipping container. Referring now to FIG. 5a , the exemplary stacked panel system 500 is shown as including 3 insulating panels stacked vertically on top of each other and a shipping container 110. As illustrated, the middle panel 520 includes multiple cut-outs 530 that can be made of differing sizes and shapes to hold payload. In the illustrated embodiment, the cut-outs are shown as being circular or cylindrical as a non-limiting example. The top and bottom panels 510 have cut-outs to hold phase change materials. All insulating panels are primarily made of natural fibers or hemp fibers such as shown on FIG. 2. To assemble the exemplary stacked panel system 500, the insulating panel 510 is inserted flat at the bottom of the shipping container 110. The insulating panel 520 is then inserted flat on top of the insulating panel 510. A third insulating panel 510 is inserted flat on top of the stack. The cut-outs 540 in the insulating panels 510 are designed to hold a device or several devices such as phase change materials. The cut-outs 530 in the insulating panel 520 are designed to hold a payload. As shown on FIG. 5b , the cut-outs 530 in the middle panel 520 are cut all the way through the insulating panel. In some implementations, the cut-outs may not pass all the way through the insulating panel 520 and as such, a bottom surface within the cut-outs can provide support for the payload.

FIG. 5b is a see-through perspective exploded view of the stacked panel system of FIG. 5a , wherein 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container. As shown on FIG. 5b , the cut-outs 540 are not cut all the way through the insulating panels 510. In this particular embodiment, the insulating panels are not encapsulated in a film. Other implementations may include insulating panels encapsulated, either in whole or in part in a film as previously described. Other implementations may have a different number of insulating panels not necessarily arranged in a vertical stack. Insulating panels may be placed side-by-side or in other arrangements. Other implementations may have cut-outs in only one panel or cut-outs in several panels. Cut-outs to a device or several devices (such as gel-packs containing phase change materials) may be placed on the sides of the panel holding the payload in addition or instead of being on top and/or at the bottom of the payload panel.

FIG. 6 is a perspective exploded view of a stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having a rectangular cut-out to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container. Referring to FIG. 6, the exemplary stacked panel system 600 includes 3 insulating panels stacked on top of each other and a shipping container 110, whereby the middle panel 610 has a rectangular cut-out 620 to hold payload and the top and bottom panels 510 have cut-outs to hold one or more devices such as phase change materials that will help maintain a desired temperature range for a prolonged period of time, such as during transportation or storage. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. The stacked panel system 600 is assembled the same way as the stacked panel system 500. The middle panel 610 has a rectangular cut-out 620 all the way through the insulating panel 610. Other implementations may have a cut-out that does not pass all the way through the insulating panel 610. Similar to the stacked panel 500, some embodiments may present a different number of insulating panels and panel arrangements with or without cut-outs.

FIG. 7 is a perspective exploded view of a wrap-around system whereby insulating panels are wrapped on the outside of the shipping container or assembly of shipping containers. Referring now to FIG. 7, the exemplary wrap-around system 700 is illustrated as including 6 insulating panels that cover the outside of an assembly of shipping containers or assembly of goods 740, such as a palletized load of boxes. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. Thus, this embodiment includes two side panels 710, two end panels 720 and a top and bottom panel 730. It should be appreciated that in some embodiments, each of the panels may be identically dimensioned (i.e. for a cubical load) or one or more of the panels may have different dimensions from one or more of the other panels. For assembly, the bottom panel 730 can be placed on a surface and the payload 740 can be stacked on top of the bottom panel 730. Once the load is in place, the side panels 710 and end panels 720 can be placed into position and finally, the top panel 730 can be placed on top of the payload 740. In some embodiments, the panels can be secured to the payload 740 by a cellophane wrapping, shipping tape, adhesive on the inside surface of the panels, straps, metal strips, clamps, a sheath, hook and nook fasteners or tape as non-limiting examples. The payload can be covered in a material, such as paper or plastic wrap and the panels can be attached thereto. Further, as illustrated in other embodiments, one or more of the panels 710, 720 and 730 may include recessed areas or cut-outs for receiving and containing devices such as phase change materials that will help maintain a desired temperature range for a prolonged period of time, such as during transportation or storage.

FIG. 8 is a perspective exploded view of a 3-panel pallet cover system whereby one insulating panel covers the bottom of the palletized payload and two panels cover two opposite sides of the palletized payload with two superimposed panels on top of the palletized payload. Referring now to FIG. 8, an exemplary 3-panel cover system 800 for a large shipping container, assembly of multiple shipping containers or assembly of goods in accordance is illustrated. For simplicity, this embodiment is referred to herein as a “pallet cover system,” although a pallet need not be used as part of this system or in its various embodiments. For simplicity, the payload illustrated as being covered in the illustrated embodiment of the pallet cover system is referred to herein as a “shipping container,” although the payload may be a single large shipping container, an assembly of shipping containers, or an assembly of goods. As shown, the 3-panel pallet cover system includes one insulating panel 810 laying on a pallet 750, a second insulating panel 820 covering the top of the shipping container 740 and also covering two opposite sides of the shipping container 740, and a third insulating panel 830 covering the top of the first insulating panel 820 and the two remaining exposed sides of the shipping container 740. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. In some embodiments, the insulating panel 820 and the insulating panel 830 are rigidly formed in a C shape or U shape. In other embodiments the insulating panel 820 and 830 may be hinged using any of a wide variety of techniques, such a scoring, creasing, using an actual hinge, using a thinner portion of material, using interlocking pieces, using tongue and groove joints, bendable or otherwise foldable along lines 822 a and 822 b for insulating panel 820 and 832 a and 832 b for insulating panel 830. Advantageously, the embodiments that can be folded are also suitable for flat-pack shipping and thus more cost effective for shipping to various locations. As such, the foldable panels can be packaged and shipped in a cost effective manner and then the panels can be folded so that they adapt to the shape of the shipping container 740. In some embodiments, the panels can be secured to the payload 740 by a cellophane wrapping, shipping tape, adhesive on the inside surface of the panels, straps, metal strips, clamps, a sheath, hook and nook fasteners or tape as non-limiting examples. The payload can be covered in a material, such as paper or plastic wrap and the panels can be attached thereto. The insulating panels may be encapsulated in a film made of materials such as but not limited to plastic, bioplastics and paper. The surface of the film may have reflective properties. In one particular and illustrative, yet non limiting, embodiment of the 3-panel pallet cover system 800, the insulating panel 810 may have a length of approximately 48 inches, a width of approximately 40 inches and a thickness of approximately 1 inch, the insulating panel 820 may have a length of approximately 136 inches, a width of approximately 40 inches and a thickness of approximately 1 inch and the insulating panel 830 may have a length of approximately 140 inches, a width of approximately 52 inches and a thickness of approximately 1 inch. Of course, these measurements are merely illustrative and insulating panels of any length, width and thickness that include the features described herein are intended to be within this disclosure and make up the overall invention, which has many different embodiments.

As previously described, the insulating panels may be held together or joined in a variety of manners. The use of adhesive or hook and loop (VELCRO) materials have been described. In addition, the use of tongue and groove type connections have been described as being molded, carved or cut into the panels to create a connection. Further, the use of tabs and spaces can be utilized such that the tabs of a panel align with the spaces of another panel, and vice versa, thereby creating a connection. Other techniques may also be used including bio-degradable tape, fasteners, pins, etc.

In some embodiments, the container may be constructed to include pockets on the interior or exterior. These pockets can also be used to receive and securely hold the insulating panels in place. It should also be appreciated that in some embodiments, the insulating panels, when assembled and secured, can operate as the shipping container as well. In such embodiments a water resistant film can be applied to the exterior of the insulating panels to further protect the contents.

While the various embodiments have been described as predominantly rectangular cubes in shape, it should be appreciated that the present invention could be applied in any shape, including spherical, orbed, pyramidal, tubular, etc. The various panels may be created in a mold, extruded or carved from larger sections of material.

Different features, variations and multiple different embodiments have been shown and described with various details. What has been described in this application at times in terms of specific embodiments is done for illustrative purposes only and without the intent to limit or suggest that what has been conceived is only one particular embodiment or specific embodiments. It is to be understood that this disclosure is not limited to any single specific embodiments or enumerated variations. Many modifications, variations and other embodiments will come to mind of those skilled in the art, and which are intended to be and are in fact covered by this disclosure. It is indeed intended that the scope of this disclosure should be determined by a proper legal interpretation and construction of the disclosure, including equivalents, as understood by those of skill in the art relying upon the complete disclosure present at the time of filing.

In the description and claims of the present application, each of the verbs, “comprise”, “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements, or parts of the subject or subjects of the verb.

The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art.

It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined by the claims that follow. 

What is claimed is:
 1. A system for maintaining temperature and protecting a payload during shipment and/or storage, the system comprising: one or more panels, wherein each of the one or more panels is composed of an insulating material that includes a natural fiber and a binder; and the one or more panels having a shape that coincides with the shape of a payload; and once the one or more panels are attached around or folded around the payload, the payload is substantially encapsulated within the one or more panels.
 2. The system of claim 1, wherein the insulating material includes hemp fibers.
 3. The system of claim 1, wherein the insulating material includes hemp fibers in a quantity that is substantially greater by volume than the quantity of the binder.
 4. The system of claim 3, wherein the insulating material is at least 40% hemp fiber and approximately 10% binder.
 5. The system of claim 1, wherein one or more of the panels define a void for receiving a phase changing material (PCM).
 6. The system of claim 1, wherein each particular panel of the one or more panels can be attached to another one or more of the one or more panels along each edges of particular panel.
 7. The system of claim 1, wherein one or more of the one or more panels is encapsulated in a film.
 8. The system of claim 7, wherein the film encapsulating one or more of the one or more panels includes a plurality of micro-perforations along at least one side of the one or more panels.
 9. The system of claim 1, further comprising a container that is sized to receive the payload encapsulated by the one or more panels.
 10. The system of claim 1, further comprising a container that is sized to receive the payload prior to the one or more panels being attached or folded around the payload.
 11. A method for maintaining temperature and protecting a payload during shipment and/or storage, the method comprising: fabricating one or more panels, wherein each of the one or more panels is composed of an insulating material that includes a natural fiber and a binder; and shaping the one or more panels such that the shape of the one or more panels coincide with the shape of a payload; and attaching or folding the one or more panels around the payload such that the payload is substantially encapsulated within the one or more panels.
 12. The method of claim 11, wherein the action of fabricating the one or more panels further comprising fabricating the one or more panels out of hemp fibers.
 13. The method of claim 11, wherein the action of fabricating the one or more panels further comprising fabricating the one or more panels out of hemp fibers such that the quantify of hemp fibers is substantially greater by volume than the quantity of the binder.
 14. The method of claim 13, wherein the action of fabricating the one or more panels out of hemp fibers such that the quantify of hemp fibers is substantially greater by volume than the quantity of the binder further comprises using at least 40% hemp fiber and approximately 10% binder.
 15. The method of claim 11, further comprising fabricating the one or more panels such that one or more of the one or more panels define a void for receiving a phase changing material (PCM) and placing a PCM into the void of the one or more panels.
 16. The method of claim 11, further comprising attaching each perimeter edge of a particular panel of the one or more panels to the perimeter edge of another one or more of the one or more.
 17. The method of claim 11, further comprising encapsulating one or more of the one or more panels in a film.
 18. The method of claim 17, further comprising creating a plurality of micro-perforations along at least one surface of at least one or more of the one or more panels.
 19. The method of claim 11, further comprising placing the payload encapsulated with the one or more panels into a container.
 20. The method of claim 1, further comprising placing the payload into a container prior to the one or more panels being attached or folded around the payload. 